Method and apparatus for pulp molding lampshades



Mag L Oct. 11, 1960 E. w. RICHARDSON 2,955,975

METHOD AND APPARATUS FOR PULP MOLDING LAMPSHADES Filed Dec. 24, 1958 3Sheets-Sheet 1 INVENTOR.

fwllay/P/dwasa/z, BY

Oct. 11, 1960 E. w. RICHARDSON 5 METHO AND APPARATUS FOR PULP MOLDINGLAMPSHADES 7 Filed Dec. 24, 1958 s Sheets-Sheet 2 )5 INVENTOR. [or/e#s/ey ixcwfisae BY n Oct. 11, 1960 E. w. RICHARDSON 2,955,975

METHOD AND APPARATUS FOR PULP MOLDING LAMPSHADES Filed Dec. 24, 1958 3Sheets-Sheet 3 INVENTQR.

ATTOR/YfX United States Patent METHOD AND APPARATUS FOR PULP MOLDINGLAMPSHADES Earle Wesley Richardson, 3109 44th St. NW. Washington, D.C.

Filed Dec. 24, 1958, Ser. No. 782,726

7 Claims. (Cl. 162-199) The present invention relates generally tolampshades and more particularly to a novel seamless shade and to anapparatus and method of making the same.

Heretofore, lampshades usually are made from sheet material requiringnumerous steps of shaping the sheet material into the skirt portion,cutting the skirt to fit the usual metal frames of the shade at eachend, sealing the side seam of the skirt, applying the finishing tape andcoloring the same to provide various desired colors. These prior methodsof making lampshades, in addition to being limited to frusto-conicalshape, are laborious and time consuming, which makes the shadesexpensive to make, due to the limited mass output of shades possiblewith such prior methods. I 1

Accordingly, it is an object of this invention to provide apparatus formass production of lamp-shades, whereby a plurality of shades may bemade in one operation in less than the time heretofore required to makeone shade from sheet material as generally outlined above.

Another object is to provide a novel seamless lamp shade, whereby theend frame structures thereof are molded or formed with the shade skirtmaterial as th skirt per se is formed. 1

A further object is to provide a novel method of making pluralities oflampshades, whereby the usual shade assembling steps are done in oneoperation to provide a substantially finished lampshade.

A further object is to provide a novel trifugual casting of lampshadesto provide various novel seamless bell-shaped formations.

Still a further object is to provide a novel apparatus, wherebybell-shaped seamless lampshades may be mass produced rapidly andinexpensively with a minimum of labor.

Yet another object is to provide apparatus adapted to form a colored andperfumed or otherwise chemically treated lampshade from fine aqueoussuspensions of comminuted paper by a simple centrifugal molding of thesaid comminuted paper into a completely formed and dehydrated coloredand perfumed lampshade.

Still a further object is to provide a novel flexible mold forcollecting comminuted matter and molding the same into shapescorresponding thereto.

With the foregoing and other objects in view, the invention consists inthe novelty of construction, combination and arrangement of the elementsof the lampshades, the apparatus producing the same and the severalsteps of the method, all respective features of which are hereinafterdescribed in detail and distinctly claimed in the appended claim.

' The description should be read in conjunction with the accompanyingdrawings, wherein:

Figure 1 is a diagrammatic view of an embodiment of the presentinvention illustrating the production of a plurality of lampshades; I

t Figure 2 is a side elevation view of one of the novel mold units as itappears removed from the supporting tank; 7

method 7 of cen- Figure 3 is a top plan view of the mold unit of FigureFigure 4 is a vertical section view of the mold unit taken along adotted line of Figure 2; and s Figure 5 is a vertical cross-sectionalview taken of a supporting tank and a mold unit mounted therein for thmolding operation. Referring to Figure l of the drawings, there isdisclosed. a diagrammatic illustration of the lampshade apparatus. and amethod of forming a plurality of lampshades in one. operating cycle ofthe apparatus. i

It is to be observed that a plurality of moldingunits A, B, and C areconnected in series and driven fiom a single power source S undercontrol of a singleoperator. Referring now more in detail to Figure 1,it is to be seen that the power source S includes an electric motor Mwith a power take-off or belt drive T from the motor to the speedreduction drive mechanism R. This speed reduction drive may be of anysuitble type and is manually controlled by a lever 8, whereby the speedof the means.

driven thereby may be manually controlled by the operator. 7

As shown in Figure 1, the speed reduction unit R is ope'rativelyconnected by a belt and pulley 9 to a shaft 10 through bevel gears 9aand 9b, which drive shaft is the driver for the several series connectedmold driving shafts 11, 12, and 13. Each of the mold driving shafts andthe drive shaft 10 therefor are jounrnalled for rotation in vertic llyspaced bearings 14 and 15 fixed to suitable. vertically spaced parallelframe bars '16 and 17. Keyed to each mold driving shaft 11, 12 and 13are pairsof vertically spaced sheaves 18, 19, 18a, 19a, and 18b and 19b.The drive shaft 10 is provided with one sheave 20 keyed thereto. Thesheave 20 of the drive shaft 10 is positioned in horizontal spacedalignment with the upper sheave 18 on shaft 11 and has a drive belt 21reeved thereabout. The belts and sheaves may be of the V-type. The lowersheave 19 on the shaft 11 is operatively connected to the lower sheave1911 on the shaft 12 by a belt 22, while the sheave 18a is operativelyconnected to the upper sheave 18!; on 'the shaft 13 by a belt 23. Thelower sheave 1% with its belt 24-may continue such series connection toany number of molding units desired. a

Each of the drive shafts 11, 12 and 13 depend below the lower supportbar 17 and are each provided with a sleeve 25, 25a and 25b whichrespective sleeves are slidably mounted on the said shafts and securedin, adjusted, position on said respective shafts by' set screws 26,where-a by the sleeves are rotatable with the shafts and axiallyadjustable on the shafts. The free ends of each respective sleeve areprovided with :a coupling means, such as a transverse pin 26a.

The tanks 27 of each respective unit A, B and C connected by outletpipes 27a 27b and 270 andvalves;

V1, V2 and V3 into a drain manifold or to a plurality of collector tanksD, E and F mounted below said mold housing tanks 27. The valves V1, V2and V3 in the T61, spective outlet pipes 27a, 27b and 270 are gang.controlled by a link L and a lever L to .openor closed positions. Thelever L may be positioned adjacent a linear. gageG Y to determine theextent of valve actuation, to control the rate of. discharge from tanks27.

The valves are opened to the extent desired when the molding tanks arefilled with water andthe lampshade molding composition is poured intothe interior of the. mold, momentarily after the molds are started, torotate] and thereby provide the centrifugal lampshade molding operation.As the tanks 27 are filled with Water, the:

same is drained off into the collector tanks D, E and F into opening 28,into pipe manifold P and to the riiileti side of a pump P to the returnline RL,and thence to the top of each respective tank 27 by said returnline..

The pump P' may be driven by a second electric motor M powered from asuitable source of electric current.

Since each of the units A, B and C are identical, a descriptionof unitA. only is suflicient to.explain the same. The several molding units arerotatably mounted in the tanks 27, which as showninFigure are formedwith an opening 28 in the bottom .thereof offset with respect to aconcentrically positioned bearing 29, which is adapted to receive abearing pin 30 supported concentrically by a foraminous insert 32, seeFigure 4, frictionally engaged within an annular wall 33 of a basemember adapted to support a mold frame. The base member further includesa top wall 34 which is provided with a central opening 35, see Figure 4,and the margin of top wall 34 overhangs the side wall 33 with aresulting circularledge 36, which is provided with a plurality ofcircumferentially spaced positioning lugs 37 for an end of a lampshademold frame 38. If desired, the said legs may be adjustable toaccommodate various sizes of mold frames.

The top wall 34 is in effect a supporting surface for the lower element38a of the mold frame and this surface is also formed with a pluralityof upstanding spacer element 39, radially inward from the lugs 37. Theseelements are to support the lower frame ring 40 of a lampshade to bemolded thereon, as hereinafter explained.

The mold frame 38 is formed according to the size and shape of alampshade to be made. For example, the same comprises the said annularlower frame element 38a, which is adapted to rest upon the supportingwall 34 within the upstanding outwardly flared lugs 37, and fixed to andextending upwardly from element 38a are a plurality of outwardly bowedstay rods 41, the respective upper ends of which are secured to arelatively larger annular frame element 42. The upper annular element 42has the rim of a sleeve of flexible molding fabric 43 secured thereto.

The molding fabric sleeve is of tubular form and is stretched around theinner side of the lower frame element 38a, and thence is pulled upwardlyalong the outside of the stay rods 41 and secured in taut condition bymeans of securing springs 44, see Figure 4, whose upper ends are fixedto the stay rods adjacently below the upper annular element 42 and whoselower ends are releasably secured to the free edge of the said moldfabric. This free edge is finished with a binding tape 45, which isprovided with a plurality of eye fasteners 46 adapted to receive thehooked ends 47 of the said respective springs 44. a

The top of the mold frame 38 is formed with an annular baffle plate 50having a tapered bore 51 and an annular right angular surface, whichserves as an anvil or land 52. This land 52 is formed with an annularflange or rim 53, which in its turn serves as a stop for the outercircumference of an upper lampshade frame ring 54 and said rim 53 fitswithin the upper frame element 42 of the mold frame, see Figure 4. Theannular baflie plate 50 is mounted on the shaft 67 of the molding.

unit 38 by means of a concentric hub ring 58 having radially extendingspokes 59, which extend into connection with the inner tapered wall 51of the annular baflle. To retain the lampshade frame ring 54 on the land52 and against the interior side of the rim 53, there are provided aplurality of vertical studs or legs 56 formed from a spider framestructure 57.

Resting on the hub ring 58 there is a coil spring 60 and superimposed inspaced vertical position above the opposite end of the spring is thefloating spider frame 57 comprising a ring or hub 61 with radial spokes62 extending and turning at right angles to form the aforesaid legs 56of the spider frame 57. The upper end of the coil of the spring 60 isengaged with the floating hub or ring 61 of frame 57 and is positionedbetween the hub rings 58 and 61 so as to be compressible or expandby anannular cam 64 supported by a third hub ring 65 with radial spokes 66 onthe shaft 67. The shaft 67 extends through the hub ring 58, spring 60,floating hub ring 61, and hub ring 65 of the cam annulus 64.

The hub rings are vertically spaced apart on the shaft 67 and rings 58and 65 are held fixed to their respective spaced relation on the shaft,by set screws 68 and 70, while the hub ring 61 floats therebetween onspring 60. The shaft 67 has its upper free end 67a notched to receivethe transverse drive pin 26a see Figure 1, and, as shown in Figure 4,has its lower end 69 bifurcated and welded to an'impeller blade 71. Thisflat impeller 71 may be bell-shaped along each vertical or elongatededge thereof to conform to the interior bell-shaped configuration of themold fabric 43.

The legs 56 of the spider frame 57 extend through guide tubes 72vertically supported and fixed on the land 52 over apertures formedtherein, and, as shown in Figure 4, will be projected through theapertures formed in the land 52, to wedge and hold the lampshade framering 54 against the stop rim 53, during the molding operation. Thisprojection of the legs 56 through the land apertures is caused by theturning of the cam annulus 64 so the cam surfaces 73 thereof engage thespokes 62 of the floating spider frame 57, thereby forcing the framedownward axially of the shaft 67 against the action of the spring 60 onwhich the hub ring 61 rests.

In assembling the lampshade mold 38, the same is positioned in a tank 27by first mounting the shaft 30 in the bearing 29, over a bafile plate75, see Figure 5. This baflle plate 75 is held raised from the bottomsur face of the tank 27 and above the outlet 28, and prevents a toorapid discharge of water from the tank during the centrifugal molding ofthe lampshades as hereinafter to be described. Then the lower lampshadeframe ring 40 is placed upon the lugs 39 of the base 34 and the moldframe 38 is placed on the base in embracing relation to the ring 40 andthe lugs 39, see Figures 2 and 4. Next the impeller 71 with the uppermold frame structure is inserted in the confines of the upper mold framering 42 with the upper frame ring 54 of the lampshade to be moldedthereto clamped on the land 52 between the legs 56 and the stop flangeor rim 53. Then, as shown in Figure 5, centering frame 77 with a centerhub 78 is placed over the shaft 67 and engaged over the rim of the tanks27 by friction elements 79 on the end of each frame member.

Next, the notched end 67a is connected to the pin 26a by lowering thesleeve 25 into drive position and subsequently tightening the wingheaded set screw 26, see Figure 1.

The drive source may now be started to provide a lampshade moldingcycle.

Operation and method of making the lampshades The method of practicingthe present invention consists, after the apparatus has been assembledas above described, of preparing a composition of comminuted paper,coloring and water, which may be perfumed or not as desired. Thecomposition is prepared by finely grinding a predetermined sized sheetof paper.

Then the tanks 27 are pumped full of water so as to completely immersethe fabric mold 43 and the power driven means is started at a relativelyslow driving speed under control of speed reduction device R. Next, thecomposition is poured into the interior of the fabric mold and thecentrifugal force of the rotary mold outwardly directs the water to thewalls of the respective tanks 27, while the solid content of thecomposition is collected and adheres to the interior surface of thefabric mold. After a few seconds of rotation, the lever L is actuated toopen the outlets 28 and the water escapes from under the bafiie plate 75into the collector tanks D, E and F.

Also, during rotation as the valves V1, V2' and V3 are opened, the waterin the lampshade making composi tion is centrifugally directed throughthe porous fabric walls of the mold material 43 and passes out theoutlet 28 with the tank water.

After the water has been discharged from the respective tanks 27, thedrive is speeded up to increase the centrifugal force of the moldrotation and thereby provides a drying action to the formerly comminutedmaterial which has now formed in a thin layer or sheet around theinterior bell-shaped surface of the mold.

Duringthe complete molding operation, the composition in the mold ismildly agitated by the stirrer or impeller 71. This provides for an evendistribution of the solids in the molding composition and prevents anyuneven or cloudy spots in the finished lampshade after it has dried andthe mold fabric is peeled therefrom.

The mold unit after the drying step is removed from the tank and thespring hooks 47 are disconnected from the eye fasteners 46. The fabricis then folded down from the outside of the frame 38 and the fabric andmold frame are demounted from the impeller mountings and the camannulus, whereby the fabric is peeled away from the finished lampshadeand the shade rings 54 and 40 are molded as part of the finished shadematerial.

The final step is to apply any desired ornamental binding around theperipheral rims of the lampshade at each end and the same is complete.Prior to this the shade is shellac dipped.

The lampshade making cycle may be continuously repeated by keeping thepower devices in operation and recycling the water into the tanks 27,with the manual addition of another charge of molding composition by theoperator.

Having set forth the present invention in accordance with certainspecific embodiments thereof, and methods of practicing the same, whatis claimed and desired to secure by United States Letters Patent is:

1. A method of making seamless lamp shades from an aqueous solution ofcomminuted cellulose material comprising the steps of stretching a limptubular fabric into a taut condition on a frame, immersing the tauttubular fabric into a volume of water, pouring a predetermined volume ofsaid aqueous solution of comminuted cellulose material into the saidstretched tubular fabric mold, imparting rotation to the same, agitatingthe material in the mold during the rotation of the mold, therebyeffecting even distribution of the material over the surface of the moldfabric slowly draining the water during said rotation and whilecollecting the cellulose material by centrifugal action on the interiorsurface of the stretched taut fabric drying the material in its moldedform by increasing the speed of rotation of the mold, and then manuallypeeling said fabric from the mold.

2. Means for centrifugally molding lampshades and the like, comprising alampshade mold frame, a porous flexible mold member with a bore mountedin said frame, said mold frame including securing means to secure saidmold member therein, a base adapted to support said mold frame and afirst annular reinforcement member to be molded in the top rim of alampshade during centrifugal molding thereof, a bearing pin projectingcentrally from the bottom of said base to rotatably mount the same, atop assembly removably mounted in the top of the said mold frame, saidassembly including a driven stu-b shaft, an impeller secured at one endto said driven stub shaft extending into the confines of the bore of themold member and formed on the opposite end with a drive coupling, saiddriven stub shaft intermediate its ends having mounted thereon aplurality of hub rings, the lowermost of said rings being connected byradial spokes to an an nular baffle plate having a radially disposedannular land having a plurality of spaced apertures, said lowermost ringbeing fixed to said driven shaft, a coil spring around said driven shaftand resting on said lowermost ring, the next adjacent hub ring definingthe center part of a spider frame, said spider frame being floatable onthe upper portion of said spring, said spider frame having" verticallegs extensible through the said apertures in'said annular in the bottomrim of a lampshade during centrifugal molding thereof in cooperationwith the extended ends of said spider frame legs, and cam means adaptedto force said floating spider frame downward, to thereby cause said legsto extend through said land apertures to clamp the said second mentionedannular reinforcement in cooperation with said annular stop.

3. The means for centrifugally molding lampshades and the like, asdescribed in claim 2 wherein the said porous flexible mold member is afabric tube and said lampshade mold frame includes-an annular ring'ateach end vertically spaced apart by outwardly bowed stay rods, and saidmold member at each respective end being en gaged around said annularframe rings.

4. Means for centrifugally molding lampshades and the like, comprising alampshade mold frame, a porousflexible mold member with a bore mountedin said mold frame, said frame including securing means to secure saidmold member therein, a base adapted to support said mold frame and afirst annular reinforcement member to be molded in the top rim of alampshade during centrifugal molding thereof, a top assembly removablymounted in the top of the said mold frame, said assembly including adriven stub shaft, an impeller secured at one end to said driven stubshaft extending into the confines of the bore of the mold member andformed on the opposite end with a drive coupling, said driven stub shaftintermediate its ends having mounted thereon a plurality of hub rings,the lowermost of said rings being connected by radial spokes to anannular bafiie plate having a radially disposed annular land having aplurality of spaced apertures, said lowermost ring being fixed to saiddriven shaft, a coil spring around said driven shaft and resting on saidlowermost ring, the next adjacent hub ring defining the center part of aspider frame, said spider frame being floatable on the upper portion ofsaid spring, said spider frame having vertical legs extensible throughthe said apertures in said annular land, said land being formed aroundits peripheral under side with an annular stop, said land serving toclamp and hold a second annular reinforcement member to be molded in thebottom rim of a lampshade during centrifugal molding thereof incooperation with the extended ends of said spider frame legs, and cammeans comprising a plurality of angular surfaces formed from the lowerrim of an annular ring, said ring being connected by a plurality ofradial spokes to a concentrically positioned hub ring, said hub ringbeing secured on said shaft above said hub ring of the said floatingspider frame, whereby said angular surfaces are progressively engageablewith the said spider frame upon rotation of said annular ring of the cammeans to provide the downward movement of said spider frame on saiddriven stub shaft.

5. A rotary mold device comprising a frame having top and bottom ringsand a plurality of interconnecting rods between the rings, a flexibletubular fabric having a top edge and a bottom edge adapted to bestretched into a desired mold shape on the said frame, said tubularfabric having the top edge thereof secured to the top ring and stretcheddownwardly therefrom within the confines of said rods and thence loopedupwardly around the said bottom ring toward the said top ring around theexterior of the said frame rods, said top edge having eye fastenersthereon, and spring fastener means detachably secured to the said frameadjacent said top ring adapted to couple to said eye fasteners, tothereby hold said mold fabric taut on the frame.

6-. A rotatable porous flexible mold and a supporting frame therefor, incombination with an enclosing tank, said frame being so shaped and soproportioned as to 7 form the flexible mold when stretched taut thereoninto a desired shape, support means for the said supporting frameforming a bearing for one end of the same, and a bearing socket at thebottom of the tank receiving said bearing, a power driving shaftincluding a telescopic section, said section in the free end thereofhaving a trans-' verse coupling pin serving as a driving connectionarranged to detachably engage the opposite end of the mold framesupport, thereby supporting the mold forrotation, said section beingvertically movable to a plane aboveand clear of the said supporting moldframe, to effect disengagement of said pin from the mold frame, tothereby permit free endwise removal of the frame from said supportmeans.

7. Apparatus for centrifugal molding of lampshades comprising a moldframe, a flexible tubular mold secured on the frame in tubular form, asupport member having a top wall with mold guide fingers and lampshadering supports, said support member having an opening in the top wall anda depending annular side wall, and a foraminous bottom wall, an upperframe supported on said mold frame, said upper frame comprising a shaftand an impeller connected to an end thereof, said shaft end opposite tothe impeller end extending vertically above the mold frame and saidupper frame and said impeller end extending into the center of saidtubular mold on the mold frame, and a plurality of superimposed spiderframes vertically spaced apart on said shaft above said impeller, saidlower spider frame having an annular baffle plate having a peripheralrim adapted to fit in the upper portion of the mold frame to therebysupport the said upper frame shaft with the impeller, and a powercoupling connection on the end of the shaft opposite to said impeller.

References Cited in the file of this patent UNITED STATES PATENTS176,344 Perrine Apr. 18, 1876 648,907 Alvord May 8, 1900 768,306 RiversAug. 23, 1904 1,956,776 Simpson May 1, 1934 2,881,680 Spengler et al.Apr. 14, 1959 FOREIGN PATENTS 1,426 Great Britain 1885 Great BritainFeb. 5, 1934

1. A METHOD OF MAKING SEAMLESS LAMP SHADES FROM AN AQUEOUS SOLUTION OFCOMMINUTED CELLULOSE MATERIAL COMPRISING THE STEPS OF STRETCHING A LIMPTUBULAR FABRIC INTO A TAUT CONDITION ON A FRAME, IMMERSING THE TAUTTUBULAR FABRIC INTO A VOLUME OF WATER, POURING A PREDETERMINED VOLUME OFSAID AQUEOUS SOLUTION OF COMMINUTED CELLULOSE MATERIAL INTO THE SAIDSTRETCHED TUBULAR FABRIC MOLD, IMPARTING ROTATION TO THE SAME, AGITATINGTHE MATERIAL IN THE MOLD DURING THE ROTATION OF THE MOLD, THEREBYEFFECTING EVE DISTRIBUTION OF THE MATERIAL OVER THE SURFACE OF THE MOLDFABRIC SLOWLY DRAINING THE WATER DURING SAID ROTATION AND WHILECOLLECTING CELLULOSE MATERIAL BY CENTRIFUGAL ACTION ON THE INTERIORSURFACE OF THE STRETHED TAUT FABRIC